Flame retardant fabric

ABSTRACT

A flame retardant fabric includes a base fabric, a bonding agent and a surface layer. The base fabric is fire-resisting and is a plain weave or knitting fabric fabricated from yarns made of flame retardant man-made fibers, or yarns made by blending, weaving or twisting the flame retardant man-made fibers and other fibers. The surface layer is a fabric, suede cloth or man-made leather or the like that is aesthetic appealing but not fire-resisting. The bonding agent bonds the base fabric and the surface layer together. The surface layer is not fire resisting, but the resulting composite fabric is flame retardant permanently. It also does not fuse or melt and can be directly carbonized to form an isolation layer.

FIELD OF THE INVENTION

The present invention relates to a flame retardant fabric and particularly to a flame retardant fabric that can resist burning permanently.

BACKGROUND OF THE INVENTION

Fire hazard is one of the threats of modern buildings that cannot be overlooked. To reduce loss and protect the safety of people during fire breaks out, many types of fire-resisting materials have been developed and used in the households. Flame retardant fabric is one of them that is commonly used on drapery, furniture and decoration.

The conventional flame retardant fabric consists of a base fabric and a surface layer. The base fabric is a plain weave or knitting fabric fabricated from fire-resisting man-made fibers, natural fibers or blending of man-made fibers and natural fibers. After the fabric is made, it is treated by dipping or coating to produce flame retardant effect. The surface layer is a fabric or man-made leather such as suede cloth or the like that is aesthetic appealing. The surface layer is bonded to the base fabric through a fire-resisting adhesive to form the finished product of the flame retardant fabric.

The flame retardant effect of the conventional flame retardant fabric is accomplished by the fire-resisting adhesive and the dipping or coating treatment of the fabric. Namely it results from the external flame retardant agents. The flame retardant effect thus formed fades away gradually after a period of time. Hence it does not have permanent fire-resisting effect and cannot fully meet user's requirements.

SUMMARY OF THE INVENTION

Therefore the primary object of the present invention is to provide a flame retardant fabric that is fire-resisting permanently and can be directly carbonized to form an isolation layer without fusing or melting. While the surface layer is not fire-resisting, the finished composite fabric is fire-resisting.

The flame retardant fabric according to the invention includes a base fabric, a surface layer and a bonding agent. The base fabric is a plain weave or knitting fabric fabricated from yarns made of flame retardant man-made fibers, or yarns made by blending, weaving or twisting the flame retardant man-made fibers and other fibers. The surface layer is a fabric or man-made leather that is aesthetic appealing such as a suede cloth. The bonding agent bonds the base fabric and the surface layer together, and can be a general adhesive without fire-resisting property.

The flame retardant fabric thus formed has the flame retardant base fabric to provide permanent fire-resisting effect. The fire-resisting effect does not diminish due to aging and the pliable feeling of the surface layer also is not affected. It also can be directly carbonized to form an isolation layer without fusing or melting.

The foregoing, as well as additional objects, features and advantages of the invention will be more readily apparent from the following detailed description, which proceeds with reference to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic view of the structure of the flame retardant fabric of the invention.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Please refer to FIG. 1, the flame retardant fabric according to the invention includes a base fabric 30, a surface layer 10 and a bonding agent 20. The base fabric 30 is a plain weave or knitting fabric fabricated from yarns made of flame retardant man-made fibers, or yarns made by blending, weaving or twisting the flame retardant man-made fibers and other fibers. The man-made fibers are modacrylic. The other fibers may be polyester, cotton, rayon, PP, nylon or the like. The composition ratio of the man-made fibers and the other fibers can be ranged between 30%-99.99% (man-made fibers) and 70%-0.01% (other fibers).

The surface layer 10 is a fabric or man-made leather which has aesthetic appeal but no fire-resisting effect, such as the ordinary fabrics used on furniture, suede cloth or man-made leather (such as a base fabric coated with Polyurethane or PVC) to provide an attractive look and pliable feeling.

The bonding agent 20 is to adhere the base fabric 30 to the surface layer 10 together to form the finished product of the flame retardant fabric. It is to be noted that the bonding agent 20 is not necessary fire-resisting. Because of the man-made fibers have fire-resisting property the resulting fabric also is flame retardant.

To Refer to the following table of the test result of a prototype of the flame retardant fabric of the invention (with the surface layer 10 made of a suede cloth, the base fabric 30 formed by blending man-made fibers and other fibers at a ratio of 55%:45%). The test is commissioned to the Taiwan Textile Research Institute, test time: Jun. 14, 2006. Test No. TCF5F060.

Test result Test Item Suede cloth Test Method Onsite Burning None BS 5852 Part 1-1979 fire-resistance Flame Butane Flame (Ignition Burn Spread None source 1) Judgment NI Onsite Burning None BS 5852 Part 1-1979 fire-resistance Flame Test by Cigarette Burn Spread None Judgment NI Onsite Burning None BS 5852 Part 2-1982 fire-resistance Flame Test on a Wooden rack Burn Spread None (Ignition source 5) Judgment NI

-   Remark 1: N1: No burning -   Remark 2: Tests of Butane flame and cigarette are coupled with a     sponge model VP45. -   Remark 3: Test on a wooden rack is coupled with a sponge model R350.

The test result listed above indicates that in the test environments of butane flame, cigarette and on a wooden rack, after ignition the conditions of burning flame and burn spread are judged no burning. Thus the flame retardant fabric of the invention is proved fire resisting.

In short, through the fire-resisting characteristic of the base fabric 30, and by bonding the base fabric 30 with the surface layer 10 together through the bonding agent 20, the flame retardant fabric of the invention can be formed. Test result shows that it has a more desirable fire resisting effect and can last permanently. There is no need to add other flame retardant agents. It can better meet user's requirements. 

1. A flame retardant fabric, comprising: a base fabric fabricated through yarns made from flame retardant man-made fibers; a surface layer; and a bonding agent adhering the base fabric to the surface layer.
 2. The flame retardant fabric of claim 1, wherein the base fabric is a knitting fabric fabricated from yarns formed by blending, weaving or twisting the flame retardant man-made fibers and other fibers at a fiber composition ratio of 30% to 99.99% for the man-made fibers and 70% to 0.01% for the other fibers.
 3. The flame retardant fabric of claim 2, wherein the man-made fibers are modacrylic, and the other fibers are selected from the group consisting of polyester, cotton, rayon, PP and nylon.
 4. The flame retardant fabric of claim 1, wherein the base fabric is a plain weave fabric fabricated from yarns formed by blending, weaving or twisting the flame retardant man-made fibers and other fibers at a fiber composition ratio of 30% to 99.99% for the mnan-made fibers and 70% to 0.01% for the other fibers.
 5. The flame retardant fabric of claim 4, wherein the man-made fibers are modacrylic, and the other fibers are selected from the group consisting of polyester, cotton, rayon, PP and nylon.
 6. The flame retardant fabric of claim 1, wherein the surface layer is selected from the group consisting of ordinary furniture fabrics, suede cloth and man-made leather,
 7. The flame retardant fabric of claim 6, wherein the man-made leather is selectively made from Polyurethane or Polyvinyl Chloride. 